How Does Drywall Production Occur?
What is Drywall?
Drywall is a common material used for construction that consists of gypsum rock layered between two sheets of paper. The gypsum rock creates a sturdy material that is still penetrable by nails and other fastening mediums. Not only is drywall convenient for construction, it also acts as fire protection. They gypsum within the drywall is largely made up of water. Because of this when exposed to fire, the drywall will not catch fire until the water has completely evaporated from the material. This can, in many cases, protect the wood framing of a structure from substantial fire damage.
Gypsum
Gypsum is a plentiful mineral found throughout the world. When processed, it contains almost half its volume worth of water in crystalline form. This explains its resistance to fire damage. Gypsum is used in many modern applications, including plaster, casts, toothpaste and even as a calcium supplement in some flours and breads. However, its largest use is in the production of drywall.
Paper
Drywall uses different types of paper, but most are made from recycled newspaper. Drywall paper is specially made to be able to accept interior paint and plaster without damaging the wall. Some drywall paper is also made with a layer of aluminum foil for installation in projects that may expose the drywall to high amounts of moisture, such as in a bathroom.
The Mixing Process
Gypsum is mixed with a small amount of starch and paper pulp to help build its core strength. Vermiculate may also be added to give the board an additional protection against fire damage. Next, water is added to the mixture along with wax, which will help the drywall resist taking in more water if it gets wet. The mixture is mixed thoroughly. During this process, air is also mixed into the final product to make the board lighter and easier to work with. The air will replace about 50% of the product once the mixing is finished.
Putting It Together
Once the mixture is correct, it is placed into a mold. On the bottom of the mold is the appropriate paper. Another layer of paper is placed on the top of the mixture. The sandwiched mixture is then sent through rollers that will compress the product to the proper dimensions. Once they have been cut and readied to go, they are passed through a hot oven. The oven evaporates out much of the water in the mixture and solidifies the boards. The drywall is then labeled and shipped out to suppliers throughout the country.
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